Method and Apparatus For Oxidizing Conductive Redeposition in TMR Sensors

ABSTRACT

A method and apparatus for oxidizing conductive redeposition in TMR sensors is disclosed. A TMR barrier layer is etched. Redeposition material is oxidized and the barrier is healed using an oxidizing agent selected from the group consisting of ozone and water vapor.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This disclosure relates in general to tunnel magnetoresistive devices,and more particularly to a method and apparatus for oxidizing conductiveredeposition in TMR sensors.

2. Description of Related Art

Magnetic recording media have been predominantly magnetic disks andmagnetic tapes. They are manufactured by forming a thin magnetic film onan A1 substrate or a resin tape. A magnetic head utilizing anelectromagnetic conversion operation is used in order to write and readmagnetic information to and from these magnetic media. This magnetichead comprises a write portion for writing the magnetic information tothe recording medium and a read portion for reading out the magneticinformation from the recording medium. A so-called “induction typehead”, which comprises a coil and magnetic poles that wrap the coil fromabove and below and are electrically connected to the coil, is generallyused for the write portion.

Magneto-resistive (MR) sensors based on anisotropic magneto-resistance(AMR) or a spin-valve (SV) effect are widely known and extensively usedas read transducers to read magnetic recording media. Such MR sensorscan probe the magnetic stray field coming out of transitions recorded ona recording medium by generating resistance changes in a reading portionformed of magnetic materials. AMR sensors have a low resistance changeratio or magneto-resistive ratio ΔR/R, whereas SV sensors have a muchhigher ΔR/R for the same magnetic field excursion. SV heads showing suchhigh sensitivity are able to achieve very high recording densities.

In a basic SV sensor, two ferromagnetic layers are separated by anon-magnetic layer. An exchange or pinning layer is further providedadjacent to one of the ferromagnetic layers. The exchange layer and theadjacent ferromagnetic layer are exchange-coupled so that themagnetization of the ferromagnetic layer is strongly pinned or fixed inone direction. The magnetization of the other ferromagnetic layer isfree to rotate in response to a small external magnetic field. When themagnetizations of the ferromagnetic layers are changed from a parallelto an anti-parallel configuration, the sensor resistance increasesyielding a relatively high MR ratio.

Recently, new MR sensors using tunneling magneto-resistance (TMR) haveshown great promise for their application to ultra-high densityrecordings. These sensors, which are known as magnetic tunnel junction(MTJ) sensors or magneto-resistive tunnel junctions (MRTJ), came to thefore when large TMR was first observed at room temperature. Like SVsensors, MTJ sensors basically include two ferromagnetic layersseparated by a non-magnetic layer. One of the magnetic layers has itsmagnetic moment fixed along one direction, i.e., the fixed or pinnedlayer, while the other layer, i.e., free or sensing layer, is free torotate in an external magnetic field. However, unlike SV sensors, thisnon-magnetic layer between the two ferromagnetic layers in MTJ sensorsis a thin insulating barrier or tunnel barrier layer. The insulatinglayer is thin enough so that electrons can tunnel through the insulatinglayer. Further, unlike SV sensors, MTJ sensors operate in CPP (CurrentPerpendicular to the Plane) geometry, which means its sensing currentflows in a thickness direction of a laminate film or orthogonal to thesurfaces of the ferromagnetic layers.

The relative magnetic direction orientation or angle of the two magneticlayers is affected by an external magnetic field such as the transitionsin a magnetic recording medium. This affects the MTJ resistance and thusthe voltage of the sensing current or output voltage. By detecting thechange in resistance and thus voltage based on the change in relativemagnetization angle, changes in an external magnetic field are detected.In this manner, MTJ sensors are able to read magnetic recording media.

In the patterning of tunnel magnetoresistive (TMR) sensors, ion millingis commonly used in recording head structures and reactive ion etching(RIE) is commonly used in magnetic random access memory (MRAM)structures. While both of these techniques are effective in patterningthe sensor material, both leave behind two artifacts, which create aparasitic resistance path, which is parallel to the remaining structure.

The first artifact is redeposited metal (redep). When patterning TMRstructures it is quite common for some metal to be milled away from thefield and redeposited on the sides of the TMR stack. However, thismaterial can be conductive. The parasitic resistance created by thisconductive material lowers the SNR in a functioning device.

The second artifact is ion damage to the barrier layer. TMR structurestypically employ an oxide insulator barrier layer. The ion milling andRIE are both prone to damage the edge of the oxide insulator barrierlayer and deplete it of oxygen. This also creates a parasiticresistance, which lowers SNR in a functioning device.

Present solutions include reactive ion oxidation of the redepositionmetal. In reactive ion oxidation energetic oxygen ions are used topartially oxidize the redep and re-oxidize or “heal” the barrier layer.Nevertheless, reactive ion oxidation has two detremental effects. First,oxygen ions have the effect of reducing the thickness and dimensions ofphotoresists and carbon layers, which may be used to pattern the TMRdevice and its subsequent biasing layers. Secondly, oxygen ions canpenetrate deeply into the sides of a TMR stack, reducing its effectivearea and damaging the free layer or pinned layer of such devices.

It can be seen that there is a need for a method and apparatus foroxidizing conductive redeposition in TMR sensors.

SUMMARY OF THE INVENTION

To overcome the limitations described above, and to overcome otherlimitations that will become apparent upon reading and understanding thepresent specification, the present invention discloses a method andapparatus for oxidizing conductive redeposition in TMR sensors.

The present invention solves the above-described problems by etching aTMR barrier layer and oxidizing redeposition material and healing thebarrier using an oxidizing agent selected from the group consisting ofozone and water vapor.

A method for oxidizing conductive redeposition in tunnelmagnetoresistive (TMR) structure in accordance with the principles ofthe present invention includes forming a TMR stack comprising a firstelectrode comprising at least a pinned layer and an antiferromagnetic(AFM) layer, a second electrode comprising a free layer and a tunnelbarrier, etching at least one of the first electrode comprising at leastthe pinned layer and the antiferromagnetic (AFM) layer, the secondelectrode comprising the free layer and the tunnel barrier using aprimarily physical etch process and applying an oxidizing agent selectedfrom the group consisting of ozone and water vapor to oxidize at least aportion of the at least one of the layers.

In another embodiment of the present invention, a magnetic read head isprovided. The magnetic read head includes an antiferromagnetic (AFM)layer, a pinned layer formed over the antiferromagnetic (AFM) layer anda tunnel barrier formed over the pinned layer, wherein the tunnelbarrier is shaped in an etching chamber and then redeposition materialproximate to the tunnel barrier is oxidized using an oxidizing agentselected from the group consisting of ozone and water vapor.

In another embodiment of the present invention, a magnetic storagedevice is provided. The magnetic storage device includes a magneticmedia for storing data thereon, a motor, coupled to the magnetic media,for translating the magnetic media, a transducer for reading and writingdata on the magnetic media and an actuator, coupled to the transducer,for moving the transducer relative to the magnetic media, wherein thetransducer includes a read sensor including an antiferromagnetic (AFM)layer, a pinned layer formed over the antiferromagnetic (AFM) layer anda tunnel barrier formed over the pinned layer, wherein the tunnelbarrier is shaped in an etching chamber and then redeposition materialproximate to the tunnel barrier is oxidized using an oxidizing agentselected from the group consisting of ozone and water vapor.

These and various other advantages and features of novelty whichcharacterize the invention are pointed out with particularity in theclaims annexed hereto and form a part hereof. However, for a betterunderstanding of the invention, its advantages, and the objects obtainedby its use, reference should be made to the drawings which form afurther part hereof, and to accompanying descriptive matter, in whichthere are illustrated and described specific examples of an apparatus inaccordance with the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings in which like reference numbers representcorresponding parts throughout:

FIG. 1 illustrates a storage system according to an embodiment of thepresent invention;

FIG. 2 illustrates one storage system according to an embodiment of thepresent invention;

FIG. 3 illustrates a slider mounted on a suspension according to anembodiment of the present invention;

FIG. 4 illustrates an ABS view of the slider and the magnetic headaccording to an embodiment of the present invention;

FIG. 5 is a side cross-sectional elevation view of a magnetic head;

FIG. 6 is an air bearing surface (ABS) view of the magnetic head of FIG.5;

FIG. 7 illustrates the connect leads coupled to the coil for the writepole piece;

FIG. 8 is a diagrammatic, cross-sectional view of a fragmentillustrating an MRAM device;

FIG. 9 is a diagrammatic illustration of a memory array comprising MRAMdevices;

FIG. 10 is an air bearing surface view of a magnetic tunnel junctionsensor;

FIG. 11 shows removal of particles in a substantially normal directionto a wafer surface;

FIG. 12 is a schematic diagram showing an ion milling apparatus;

FIG. 13 shows a high-frequency induction type RIE apparatus;

FIG. 14 is a flow chart of the method for oxidizing conductiveredeposition in TMR sensors according to an embodiment of the presentinvention; and

FIG. 15 shows a dosing chamber for applying an oxidizing agent selectedfrom the group consisting of ozone and water vapor according to anembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

In the following description of the embodiments, reference is made tothe accompanying drawings that form a part hereof, and in which is shownby way of illustration the specific embodiments in which the inventionmay be practiced. It is to be understood that other embodiments may beutilized because structural changes may be made without departing fromthe scope of the present invention.

The present invention provides a method and apparatus for oxidizingconductive redeposition in TMR sensors. In an embodiment of the presentinvention, a TMR barrier layer is etched. Redeposition material isoxidized and the barrier is healed using an oxidizing agent selectedfrom the group consisting of ozone and water vapor.

FIG. 1 illustrates an exemplary storage system 100 according to thepresent invention. A transducer 110 is under control of an actuator 120,whereby the actuator 120 controls the position of the transducer 110.The transducer 110 writes and reads data on magnetic media 130. Theread/write signals are passed to a data channel 140. A signal processor150 controls the actuator 120 and processes the signals of the datachannel 140 for data exchange with external Input/Output (I/O) 170. I/O170 may provide, for example, data and control conduits for a desktopcomputing application, which utilizes storage system 100. In addition, amedia translator 160 is controlled by the signal processor 150 to causethe magnetic media 130 to move relative to the transducer 110. Thepresent invention is not meant to be limited to a particular type ofstorage system 100 or to the type of media 130 used in the storagesystem 100.

FIG. 2 illustrates one particular embodiment of a multiple magnetic diskstorage system 200 according to the present invention. In FIG. 2, a harddisk drive storage system 200 is shown. The system 200 includes aspindle 210 that supports and rotates multiple magnetic disks 220. Thespindle 210 is rotated by motor 280 that is controlled by motorcontroller 230. A combined read and write magnetic head 270 is mountedon slider 240 that is supported by suspension 250 and actuator arm 240.Processing circuitry exchanges signals that represent information withread/write magnetic head 270, provides motor drive signals for rotatingthe magnetic disks 220, and provides control signals for moving theslider 260 to various tracks. Although a multiple magnetic disk storagesystem is illustrated, a single magnetic disk storage system is equallyviable in accordance with the present invention.

The suspension 250 and actuator arm 240 position the slider 260 so thatread/write magnetic head 270 is in a transducing relationship with asurface of magnetic disk 220. When the magnetic disk 220 is rotated bymotor 280, the slider 240 is supported on a thin cushion of air (airbearing) between the surface of disk 220 and the ABS 290. Read/writemagnetic head 270 may then be employed for writing information tomultiple circular tracks on the surface of magnetic disk 220, as well asfor reading information therefrom.

FIG. 3 illustrates a sensor assembly 300. In FIG. 3, a slider 320 ismounted on a suspension 322. First and second connections 302 and 308connect leads from the sensor 318 to leads 310 and 314, respectively, onsuspension 322 and third and fourth connections 304 and 306 connect tothe write coil (not shown) to leads 312 and 316, respectively, onsuspension 322.

FIG. 4 is an ABS view of slider 400 and magnetic head 410. The sliderhas side rails 430 and 460 and a center rail 420. A magnetic head 410 isprovided and may be supported on the central rail 420. However, the headmay be disposed otherwise, e.g., on a side rail. The rails 420, 430 and460 extend from a cross rail 440. With respect to rotation of a magneticdisk, the cross rail 440 is at a leading edge 450 of slider 400 and themagnetic head 410 is at a trailing edge 470 of slider 400.

The above description of a typical magnetic recording disk drive system,shown in the accompanying FIGS. 1-4, is for presentation purposes only.Storage systems may contain a large number of recording media andactuators, and each actuator may support a number of sliders. Inaddition, instead of an air-bearing slider, the head carrier may be onethat maintains the head in contact or near contact with the disk, suchas in liquid bearing and other contact and near-contact recording diskdrives.

FIG. 5 is a side cross-sectional elevation view of a magnetic head 540.The magnetic head 540 includes a write head portion 570 and a read headportion 572. The read head portion 572 includes a sensor 574. FIG. 6 isan ABS view of the magnetic head of FIG. 5. The sensor 574 is sandwichedbetween first and second shield layers 580 and 582. In a piggyback headas shown in FIG. 5, the second shield layer (S2) 582 and the first polepiece (P1) 592 are separate layers. The first and second shield layers580 and 582 protect the MR sensor element 574 from adjacent magneticfields. More conventionally, the second shield 582 also functions as thefirst pole (P1) 592 of the write element, giving rise to the term“merged MR head.” However, the present invention is not meant to belimited to a particular type of MR head.

In response to external magnetic fields, the resistance of the sensor574 changes. A sense current Is conducted through the sensor causesthese resistance changes to be manifested as voltage changes. Thesevoltage changes are then processed as readback signals by the signalprocessing system 350 shown in FIG. 3.

The write head portion of the magnetic head includes a coil layer 584sandwiched between first and second insulation layers 586 and 588. Athird insulation layer 590 may be employed for planarizing the head toeliminate ripples in the second insulation layer caused by the coillayer 584. An insulation layer 542 is formed over the second pole piecelayer 594. The first, second and third insulation layers are referred toin the art as an “insulation stack.” The coil layer 584 and the first,second and third insulation layers 586, 588 and 590 are sandwichedbetween first and second pole piece layers 592 and 594. The first andsecond pole piece layers 592 and 594 are magnetically coupled at a backgap 596 and have first and second pole tips 598 and 501 which areseparated by a write gap layer 502 at the ABS 548. The first pole piecelayer 592 is separated from the second shield layer 582 by an insulationlayer 503.

FIG. 7 illustrates a view of the connect leads 520, 522 coupled to thecoil 584 for the write pole piece 594. As shown in FIGS. 3-7, first andsecond connections 304 and 306 connect leads from the sensor 574 toleads 312 and 314 on the suspension 344, and third and fourthconnections 316 and 318 connect leads 520 and 522 from the coil 584 (seeFIG. 7) to leads 324 and 326 on the suspension. While FIG. 7 shows an“overpass” design, those skilled in the art will recognize that otherdesigns, such as an “underpass” design are possible. Thus, the presentinvention is not meant to be limited to a specific write head design.

FIG. 8 illustrates a diagram 800 of an exemplary an MRAM device 812.More specifically, diagram 800 comprises a substrate 814 having aconductive line 816 formed thereover, and device 12 is formed over theconductive line. Substrate 814 can comprise an insulative materialand/or may comprise numerous materials and layers. The term “substrate”refers to any supporting structure, including, but not limited to, thesemiconductive substrates.

Conductive line 816 can comprise, for example, various metals and metalalloys. The MRAM device 812 formed over line 816 comprises three primarylayers, 818, 820 and 822. Layers 818 and 822 comprise soft magneticmaterials. Layer 820 comprises a non-magnetic material. The non-magneticmaterial is an electrically insulative material (such as, for example,aluminum oxide (Al₂O₃) or silicon dioxide).

Layers 818 and 822 have magnetic moments associated therewithillustrated by arrows 819, 821. In the shown construction, the magneticmoment in layer 822 is anti-parallel to the magnetic moment in layer818. Such is one of two stable orientations for the magnetic moment oflayer 822 relative to that of 818, with the other stable orientationbeing a parallel orientation of the magnetic moment in layer 822relative to the moment in layer 818. One of layers 818 and 822 can havea pinned orientation of the magnetic moment therein, and such can beaccomplished by providing a hard magnetic layer, or in other words apermanent magnet (not shown) adjacent the layer. The layer having thepinned magnetic moment can be referred to as a reference layer.

In operation, MRAM device 812 can store information as a relativeorientation of the magnetic moment in layer 822 to that in layer 818.Specifically, one of the anti-parallel or parallel orientations of themagnetic moments of layers 818 and 822 can be designated as a 0, and theother of the anti-parallel and parallel orientations can be designatedas a 1. Accordingly, a data bit can be stored within device 812 as therelative orientation of magnetic moments in layers 818 and 822.

A conductive line 824 is shown over layer 822, and such conductive lineextends into and out of the plane of the page. Conductive line 824 cancomprise, for example, one or more metals and/or metal alloys,including, for example, copper and/or aluminum. An insulative material826 extends over conductive line 816, and along the sides of bit 812 andconductive line 824.

The diagram 800 is an exemplary MRAM construction, and it is to beunderstood that various modifications can be made to the construction810 for various applications. For instance, one or more electricallyinsulative layers (not shown) can be provided between device 812 and oneor both of conductive lines 816 and 824. Also, one or more magneticlayers (not shown) can be stacked within device 812 in addition to theshown layers 818 and 822.

In operation, data is written to MRAM device 812 by passing currentalong the conductive lines 816 and 824 to change the relative magneticorientation of layers 818 and 822 (i.e., to flip the relativeorientation from parallel to anti-parallel, or vice versa). In theory,the relative orientation of layers 818 and 822 can be flipped by passingsufficient current along only one of lines 816 and 824, but in practiceit is generally found to be advantageous to utilize both of lines 816and 824 in writing information to device 812. Specifically, some currentis initially passed along one of the lines 816 and 824 to induce amagnetic field in device 812 which starts to flip the relative magneticorientation of layers 818 and 822, and then current is passed along theother of layers 816 and 824 to complete the flip of the relativemagnetic orientation within device 812.

The operation of reading information from device 812 can utilize eitherinductive sensing or magnetoresistive sensing to detect the relativemagnetic orientation of layers 818 and 822 within the device. Thereading can utilize one or both of lines 816 and 824, and/or can utilizea separate conductive line (not shown).

It is advantageous to have lines 816 and 824 be orthogonal to oneanother at the location of device 812 to maximize the complementaryeffect of utilizing both of conductive lines 816 and 824. A device thatutilizes a pair of independently controlled conductive lines for writingto and/or reading from an MRAM device is typically referred to as ahalf-select MRAM construction. Typically, one of the orthogonal lines816 and 824 will be designated as inducing field H_(x) parallel to themoments of layers 822 and 818 (with layer 824 inducing H_(x) in theshown embodiment), and the other will be designated as inducing fieldH_(y) perpendicular to the moments of layers 822 and 818 (with layer 816inducing H_(y) in the shown embodiment). Accordingly, layers 816 and 824induce orthogonal magnetic fields within MRAM device 812.

As discussed above, a single MRAM device can store a single bit ofinformation. Accordingly, in applications in which it is desired toprocess multiple bits of information, it is generally desired to utilizea plurality of MRAM devices, with each of the devices independentlystoring bits of information. The devices will typically be arranged inan array, and an exemplary array 950 of MRAM devices is illustrated inFIG. 9. The array comprises individual MRAM devices 952, 954, 956, 958,960 and 962. The array also comprises a plurality of conductive lines964, 966 and 968 utilized for inducing H_(x), and a plurality ofconductive lines 970 and 972 utilized for inducing H_(y).

FIG. 10 shows one variant of a current-perpendicular-to-plane (CPP) TMRsensor 1000 according to an embodiment of the present invention. Sensor1000 includes a ferromagnetic reference layer 1006 with a fixed magneticmoment oriented transversely (into the page) and a ferromagnetic freelayer 1010 with a rotatable magnetization vector, which can rotate aboutthe longitudinal direction in response to transverse magnetic signalfields. The direction of the magnetic moment of the reference layer 1006is typically fixed by exchange coupling with an antiferromagnetic layer1004. The exchange-pinned reference layer 1006 and free layer 1010 arespaced apart by an electrically insulating tunnel barrier layer 1008.Hard bias layers 1012 are electrically insulated from the sensor stackand the top electrical lead 1016 by insulating layers 1014 and 1018respectively. Hard bias layers 1012 provide a longitudinal biasingmagnetic field to stabilize the magnetization of the free layer 1010.Sensor 1000 further includes a layer 1002, which may act as anelectrical contact. Those skilled in the art will recognize that thepresent invention is not meant to be limited to the particular CPP TMRsensor 1000 shown in FIG. 10. Rather, other configurations, e.g., onethat uses an in stack bias, are within the scope of the presentinvention.

FIG. 11 shows removal of particles in a substantially normal directionto a wafer surface, as shown by arrows 1166. The height of layer 1133 isalso reduced, and that layer as well as the sensor layers may be thinnedslightly. The particular sensor embodiment shown in FIG. 11 includes afirst magnetically permeable shield 1102, which in the embodiment shownin FIG. 11 includes tapered regions 1106. However, tapered regions 1106are not essential and in some designs not present. In fact, in somedesigns, etching does not go down past the pinned layer 1118.

An optional electrically conductive, nonmagnetic spacer 1110, which mayfor instance be formed of copper (Cu) or a noble metal, adjoins thetapered section 1106 of the first shield. An optional electricallyconductive seed layer 1112 made of a material such as tantalum (Ta) ornickel-iron-chromium (NiFeCr) is disposed between an antiferromagneticlayer 1115 and spacer 1110. Antiferromagnetic layer 1115 stabilizes amagnetic moment of an adjoining pinned ferromagnetic layer 1118 in adirection toward or away from the media. A tunneling layer 1120 made ofnon conducting material such as a dielectric separates pinned layer 1118from a free ferromagnetic layer 1122, which has a magnetic moment thatis able to rotate in the presence of a magnetic field from a media. Inthe absence of a magnetic field from a media, free layer 1122 has amagnetic moment substantially parallel to the media surface. A secondoptional electrically conductive, nonmagnetic spacer 1125 may beprovided. A layer 1133 comprising a photoresist layer or hard mask, suchas carbon, adjoins the spacer 1125.

FIG. 12 is a schematic diagram 1200 showing an ion milling apparatus. InFIG. 12, a specimen 1210 is supported by support arms 1230 of a specimenholder in vacuum chamber 1234 for recording head applications or a Siwafer for MRAM applications. Suitable means, such as a high vacuum pump1236 capable of reducing the pressure in chamber 1234 are used toevacuate the chamber. The pedestal 1238 of the specimen holder is fittedonto a holder mount 1240. Holder mount 1240 may be rotated, by suitablerotary drive means (not shown), to cause specimen 1210 to rotate duringion milling. A gas introducing port 1235 is provided in the chamber1234. An ion milling gas is supplied through the gas introducing port1235, while excitation is provided by RF source 1260.

The etching process may also be realized using a reactive ion etching(RIE) process. FIG. 13 shows a high-frequency induction type RIEapparatus. In FIG. 13, numeral 1313 denotes a substrate, 1329 denotes avacuum pump, 1330 denotes a specimen exchanging chamber, 1335 denotes agas introducing port, 1336 designates plasma and 1338 denotes a coil.The apparatus now concerned features a high plasma density. An etchinggas is fed through the gas introducing port 1335 with the plasma 1336being excited by applying a high-frequency electric power to the coil1338 while a bias voltage is applied to the substrate, whereby ions arecaused to impinge into the substrate to effectuate the process.

During the patterning of tunnel magnetoresistive (TMR) sensors, anetching process such as reactive ion etching or ion milling etching areused. The etching process is realized primarily by resorting to aphysical removal effect based on high-energy ion impact. Consequently,all the particulates sputtered by the physical etching are not alwaysremoved by the vacuum pump but some part of the sputtered particulatesare usually deposited on the remaining structure. This phenomenon willbe referred to as the re-deposition. As described earlier, theredepostion material can be conductive and cause parasitic resistance,which lowers the SNR in a functioning device. Also, there may be iondamage to the barrier layer. TMR structures typically employ an oxideinsulator barrier layer. The ion milling and RIE are both prone todamage the edge of the oxide insulator barrier layer and deplete it ofoxygen. This also creates a parasitic resistance that lowers SNR in afunctioning device.

FIG. 14 is a flow chart 1400 of the method for oxidizing conductiveredeposition in TMR sensors according to an embodiment of the presentinvention. In FIG. 14, a TMR stack is formed comprising a first magneticlayer, a second magnetic layer, and a non-magnetic layer between thefirst and second magnetic layers 1410. The TMR stack is disposed in avacuum chamber of an etching device 1420. At least one of the firstmagnetic layer, second magnetic layer and non-magnetic layer is etchedusing a primarily physical etch process in a reaction chamber 1430. Anoxidizing agent selected from the group consisting of ozone and watervapor is applied to oxidize at least a portion of the at least one ofthe layers 1440. While it is possible to introduce ozone or water vaporduring the etching process, e.g., the ion beam etching process,embodiments of the present invention may also include first etching andthen oxidizing the TMR stack. Ozone and water vapor, when applied in acontrolled manner and at elevated temperature, can readily oxidize theredeposition material and heal the TMR barrier layer. The elevatedtemperature may be 100° C. and greater. Water vapor, when similarlyapplied, is known to readily oxidize metal materials. The oxidation maybe performed at a variety of temperatures from room temperature up untilthe damage threshold of the TMR stack, e.g., around 300 C.

Either of these procedures may be performed in a vacuum system, e.g., anatomic layer deposition (ALD) reactor. FIG. 15 shows a dosing chamber1500 for oxidizing redeposition material and healing the barrier usingan oxidizing agent selected from the group consisting of ozone and watervapor according to an embodiment of the present invention. In FIG. 15, avacuum chamber 1502 includes a substrate holder 1504 for holding anetched TMR stack 1510. A pump 1520 reduces the pressure in chamber 1502to evacuate the chamber 1502. An oxidizing agent source 1540 is providedfor generating the ozone or the water vapor. The oxidizing agent source1540 subjects the TMR stack 1510 in the vacuum chamber 1502 to acontrolled dose of ozone or water vapor. For example, a water vaporsource might consist of a “bubbler” arrangement in which a carrier gassuch as Ar or N₂ is bubbled through water vapor either at roomtemperature or at elevated temperature and then delivered through theinlet to the vacuum system 1502. For the ozone generator, a commerciallyavailable instrument may be used, which takes O₂ as its input and usesan electrical discharge to turn it into high concentrations of ozone.The water vapor or ozone can be applied in a continuous or pulsed basisas necessary. In addition, the surface can then be terminated withlayers of additional oxide, which act as an insulating spacer betweenthe TMR sensor and any subsequent bias materials.

The foregoing description of the exemplary embodiment of the inventionhas been presented for the purposes of illustration and description. Itis not intended to be exhaustive or to limit the invention to theprecise form disclosed. Many modifications and variations are possiblein light of the above teaching. It is intended that the scope of theinvention be limited not with this detailed description, but rather bythe claims appended hereto.

1-12. (canceled)
 13. A magnetic read head, comprising: anantiferromagnetic (AFM) layer; a pinned layer formed over theantiferromagnetic (AFM) layer; and a tunnel barrier formed over thepinned layer, wherein the tunnel barrier is shaped in an etching chamberand then redeposition material proximate to the tunnel barrier isoxidized using an oxidizing agent selected from the group consisting ofozone and water vapor.
 14. The magnetic read head of claim 13 furthercomprising terminating oxidized surfaces with layers of additional oxidethat act as an insulating spacer over the sensor.
 15. A magnetic storagedevice, comprising: a magnetic media for storing data thereon; a motor,coupled to the magnetic media, for translating the magnetic media; atransducer for reading and writing data on the magnetic media; and anactuator, coupled to the transducer, for moving the transducer relativeto the magnetic media; wherein the transducer includes a read sensorcomprising: an antiferromagnetic (AFM) layer; a pinned layer formed overthe antiferromagnetic (AFM) layer; and a tunnel barrier formed over thepinned layer, wherein the tunnel barrier is shaped in an etching chamberand then redeposition material proximate to the tunnel barrier isoxidized using an oxidizing agent selected from the group consisting ofozone and water vapor.
 16. The magnetic read head of claim 14 furthercomprising terminating oxidized surfaces with layers of additional oxidethat act as an insulating spacer over the sensor.